PRELIMINARY DESIGN OF PROPYLENE GLYCOL PLANT FROM PROPYLENE OXIDE AND WATER USING ACID Preliminary Design of Propylene Glycol Plant from Propylene Oxide and Water Using Acid Catalyst with Capacity of 50,000 Ton/Year.

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PRELIMINARY DESIGN OF PROPYLENE GLYCOL PLANT

FROM PROPYLENE OXIDE AND WATER USING ACID

CATALYST WITH CAPACITY OF 50,000 TON/YEAR

By: Aisyah Hanifah

D500122004 Supervisor:

Eni Budiyati, S.T., M.Eng Ir. Nur Hidayati, M.T., Ph.D.

CHEMICAL ENGINEERING DEPARTMENT FACULTY OF ENGINEERING

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MOTTO

Ever Tried Ever Failed No Matter

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v

DEDICATION

This work is dedicated for:

Umi is the one who give a spirit for me, advise me, and also give me a direction

so that I can finish this final report.

Abi is my role model. Even he is hard but I know that he did for me. Thanks for

your money. I will replace it later and make you feel happy

My brother Muhammad Taufik Al-Haqim and Muhammad Zaki Faizal, you are

good brother in the world. Reach your dream. Do not disappoint us.

My partner Diah Ayu Anggraeni. When I am so lazy, you are the one who always

give me a spirit. Thanks mba di 

For my grandmother and grandfather. Thank you for your praying. 

Nanik, Anggi, Rendra, Mala, Mba Delta and Salam from international class and

listi you are everything for me. No one can replace you. Thanks for your spirit. I

will keep my finger cross for all of you 

For my friends, chemical engineering, 2012. Thanks for togetherness. Thanks for

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PREFACE

Bissmillahirrahmanirrohim

The author thanks Allah SWT for His blessing and mercy, in completing the

final project en titled “Preliminary Design of Propylene Glycol Plant from

Propylene Oxide and Water using Acid Catalyst with Capacity of 50,000

Ton/Year”.

This report is final task as a requirement to obtain bachelor degree (S.T) in

The Department of Chemical Engineering Faculty of Universitas Muhammadiyah

Surakarta. Upon finishing this task, it is expected to understand the theory that have

been studied and can be used as alternative industry plant in the future.

The author aware that the completing of The Final Project Report is

impossible without the help of adviser and other parties. Therefore, in this

opportunity authors are grateful to all those who helped completing The Final

Project Report, in particular to:

1. Allah SWT who has given me His mercy and His blessing.

2. Rois Fatoni, ST, MSc, Ph.D. as Head of Department of Chemical

Engineering of Universitas Muhammadiyah Surakarta.

3. Ms. Eni Budiyati, S.T., M.Eng as first supervisor

4. Ir. Nur Hidayati, M.T., Ph.D. as second supervisor

5. All the lecturer in Department of Chemical Engineering of Universitas

Muhammadiyah Surakarta.

6. My partner Diah Ayu Anggraeni and All my friends from international

class 2012

7. My Family who always gives a support to the Author.

Author aware that this report is far from perfect because of limited

capabilities and existing deficiencies in making final task Report. Author hope

that the report will be useful for those who may concern

Surakarta, November 2016

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vii

TABLE OF CONTENTS

TITLE ... i

APPROVAL ... ii

AUTHOR’S DECLARATION ... iii

MOTTO ... iv

DEDICATION ... v

PREFACE ... vi

TABLE OF CONTENTS ... vii

LIST OF TABLE ... ix

TABLE OF FIGURE ... xii

ABSTRACT ... xiii

CHAPTER I INTRODUCTION ... 1

1.1Background ... 1

1.2Capacity of The Plant... 1

1.3Literature Review... 5

1.4The Usefulness of Products ... 6

1.5Properties of Physical and Chemical Raw Materials and Products ... 7

CHAPTER II PROCESS DESCRIPTION ... 11

2.1The Specification of Raw Materials and Products ... 11

2.2The Process Concept ... 12

2.3The Thermodynamic Review ... 12

2.4The Flowchart ... 15

2.5The Process Stages ... 15

2.6The Flowchart of Material Balance and Heat Balance ... 16

2.7The Plant Layout and Equipment ... 30

CHAPTER III THE SPESIFICATION of THE EQUIPMENT ... 36

3.1Main Equipment... 36

3.2Supporting Equipment ... 42

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4.2Liquid Waste Treatment Unit ... 73

CHAPTER V MANAGEMENT 5.1Company ... 75

5.2Organizational Structure ... 76

5.3Employee Status and Salary Status ... 82

5.4Health and Safety ... 87

5.5Production Management ... 88

5.6Production Plant ... 88

5.7Production Control ... 89

CHAPTER VI ECONOMICAL ANALYSIS ... 91

6.1Basic Calculation ... 91

6.2Cost Calculation ... 93

6.3General Expenses ... 95

6.4Feasibility Analysis ... 96

6.5The Result of Calculation ... 97

CHAPTER VII CONCLUSION ... 104

BIBLIOGRAPHY ... 105

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ix

LIST OF TABLE

Table 1.1 Import of propylene glycol in Indonesia from 2011 to 2015………….2

Table 1.2 Data of propylene glycol production capacity abroad………....3

Table 2.1 ΔG°f value each components ……….……..12

Table 2.2 Value of ΔH°f each component……….……13

Table 2.3 Component of Mass Flow……….………….17

Table. 2.4 Mass balance of Mixer (M-110) ………..18

Table. 2.5 Mass balance of Reactor (R-120) ………18

Table. 2.6 Mass balance of Reactor ( R-130) ………18

Table 2.7 Mass balance of Distillation Tower (D-140) ………19

Table 2.8 Mass balance of Neutralizer (R-150).………19

Table 2.9 Mass balance of Decanter (H-160).………...20

Table 2.10 Mass balance of Distillation Tower (D-170) ………..20

Table 2.11 Mass balance of Distillation Tower (D-180) ………..21

Table. 2.12 The Total of material balance……….22

Table. 2.13 Heat balance of Mixer (M-110) ……….24

Table. 2.14 Heat balance of Reactor (R-120) ………...23

Table. 2.15 Heat balance of Reactor (R-130) ………...24

Table. 2.16 Heat balance of Heat Exchanger (E-132) ………..24

Table. 2.17 Heat balance of Distillation tower (D-140) ………24

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Table. 2.19 Heat balance of Cooler (E-143) ……….25

Table. 2.21 Heat balance of neutralizer (R-150) ………...26

Table. 2.22 Heat balance of Decanter (H-160) ………....….27

Table. 2.23 Heat balance of Heat Exchanger (E-174) ………..28

Table 2.27 Building plant of Propylene glycol with capacity of 50,000 tons / year……….……….………...31

Table 4.1. Need of cooling water (kg/h) ………...69

Table 4.2. Need of water for steam (kg/h) ………69

Table 4.3. Power in process unit……….………...71

Table 4.4. Power in utility unit……….……….72

Table 5.1 Schedule for each group……….………84

Table 5.2 Position and requirements……….………….84

Table 6.1 Cost Index Chemical Plant Year 1990-2010……….92

Table 6.2 Physical Plant Cost………97

Table 6.3 Fixed Capital Cost (FCI) ………...99

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xi

Table 6.5 Manufacturing Cost………...99

Table 6.6 General Expense………..100

Table 6.7 Fixed Cost………101

Table 6.8 Variable Cost………...102

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TABLE OF FIGURE

Figure 1.1 Need of Propylene glycol in Indonesia………...2

Figure 2.1 Flowchart of Qualitative……….…………..15

Figure 2.2The flowchart of mass balance………..17

Figure 2.3 Layout of Precipitated Silica Plant………...32

Figure 2.4 Layout of equipment of Propylene………...34

Figure 4.1. Diagram process of water treatment………62

Figure 5.1 Organizational Structure………...81

Figure 6.1 Relationship between Years and Cost Index………93

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xiii

Abstrak

Di Indonesia, pabrik propilen glikol adalah industry yang menawarkan kesempatan

baik untuk Negara. Propilen glikol dihasilkan dari reaksi propilen oksida dan air

menggunakan katalis asam dengan perbandingan propilen oksida: air: methanol

adalah 43,04: 802,8: 71,87 lbmol. Proses menggunakan reaktor RATB (Reaktor

Alir Tangki Berpengaduk). Reaktor beroperasi pada suhu 30°C dan tekanan 1 atm.

Reaksi pada reaktor berjalan pada kondisi fase cair, irreversible dan eksotermis.

Unit pendungkung dari pabrik terdiri dari unit penyedia air, unit suplai uap air,

listrik dan kebutuhan bahan bakar dan laboratorium untuk menjaga kualitas bahan

baku dan produk dalam keadaan standar. Perusahan ini adalah perusahaan

perseroan terbatas (PT) dengan system organisasi terstruktur dan pegawai.

Perusahan ini terletak di Gresik profinsi Jawa. Terlihat dari analisis ekonomi bahwa

Percent Return on Investment (ROI) sebelum pajak adalah 25.42 % dan ROI setelah

pajak adalah 17.79 %. Pay out Time (POT) sebelum pajak adalah 2.8 tahun. Break

Even Point (BEP) adalah 45.96 %, Shut down Point (SDP) adalah 21.51 %,

menghasilkan Discounted Cash Flow (DCF) 30.28 %, dari data analisi yang

didapatkan, bisa disimpulkan bahwa pabrik menguntungkan dan kemungkinan

untuk dibangun.

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Abstract

In Indonesia, propylene glycol plant is an industry that can provide a good

opportunity for the country. Propylene glycol is produced by a reacting of propylene

oxide and water using an acid catalyst by a ratio of propylene oxide: water:

methanol is 43.04: 802.8: 71.87 lbmol. The process using CSTR reactor

(Continuous stirred tank reactor). The reactor operates at temperature of 30°C and

a pressure of 1 atm. The reaction in the reactor is carried out at liquid phase,

irreversible, and exothermic condition. Supporting units of the plant consists of the

units of the water provider, the unit of steam supply, electricity and fuel needs, and

laboratories to maintain the quality of materials and products to conform to the

standards. This company is a limited liability company (PT) with a system of

organizational structure and staff. The company is located in Gresik Java Province.

The economic analysis showed that Pretax Percent Return on Investment (ROI) is

25.42 % and ROI after tax is 17.79 %. Pay out Time (POT) before taxed is 2.8 year.

Break Even Point (BEP) of 45.96 %, Shut down Point (SDP) of 21.51 %, and was

obtained Discounted Cash Flow (DCF) of 30.28 %, were obtained the data

feasibility analysis, it can be concluded that the plant is profitable and feasible to

be established.